Multiple MLCC Modules

ABSTRACT

An improved module is provided. The module comprises a multiplicity of electronic components wherein each electronic component comprises a first external termination with at least one first longitudinal edge and a second external termination with at least one second longitudinal edge. A first lead is connected to the first longitudinal edge by a first interconnect and a second lead is connected to the second longitudinal edge by a second interconnect.

BACKGROUND

This invention is related to the art of electrical component packaging.More specifically, the present invention relates to an electricalcomponent package, or module, comprising multiple electrical componentstherein to provide a specific function that can be incorporated into anelectrical circuit assembly. More particularly, the present invention isrelated to the use of high temperature electrically conductiveinterconnect materials to attach multiple components, particularlyincluding multilayered ceramic capacitor (MLCC) components, to a commonlead or component carrier material in an array within a singleencapsulated package for attachment to an electrical circuit.

Electrical component packages exist with an over molded single activedevice, such as integrated circuits, in the forms of leadless chipcarrier (LCCC), plastic leaded chip carrier (PLCC), transistor outlinesuch as TO-220, ball grid arrays (BGA), quad flat package (QFP), singlein-line package (SIP), dual in-line packaging (DIP), etc. Morespecifically, capacitor packages exist for multilayered ceramiccapacitor (MLCC) components in the form of axial leaded packages with asingle MLCC component, and radial leaded packages with a single MLCCcomponent. Axial and radial MLCC component packages have a limitedcapacitance based on the maximum geometry of a single MLCC with thecapability of meeting the form factor requirements of existing packagedesigns. Other capacitor packages comprising multiple capacitors existin the form of MLCC component stacks. These MLCC stack packages containmultiple MLCC's of the same size and value capacitors with leadsattached to the end of the external terminations of the MLCC. The totalcapacitance of stacked capacitor packages can only be a multiple of theparticular component used for the stack.

If the capacitance requirement for a circuit design exceeds the value ofa single MLCC, multiple capacitors must be placed on the circuit boardor a different type of capacitor must be selected. The placement ofredundant capacitors requires more circuit board space and additionalassembly time both of which are contrary to the ongoing desires forfurther miniaturization and increased efficiency. Selection of analternate type of capacitor may not meet the superior electricalperformance provided in MLCC's and the superior electrical performanceis typically desirable in modern electrical circuits. This has led tothe introduction of stacked MLCC component packages that have a highercapacitance, require less board space than individually placedcomponents, and have the equivalent assembly time for the placement of asingle component. However, because the MLCC components are stacked, theymust be of the same case size to allow the terminations of eachindividual MLCC to interface with the end of the external termination ofadjacent MLCCs. In the case of a leaded MLCC stack, the individual MLCCsizes must be the same to interface the leads that connect to the endsurface of the MLCC termination.

MLCC components are subject to a failure mode represented by cracksformed due to the board flexing when exposed to a high vibration and/ora high temperature environment. MLCC packages with leads are oftenrequired in electrical circuit designs wherein the lead isolates theboard flexure from the MLCC thereby mitigating the stress that reachesthe MLCC component. However, there are limitations to the assembly ofleaded stacks because of the aforementioned lead attachment interfaceand size and shape variations in the MLCC component that are inherent inthe manufacturing processes.

Therefore, a leaded multiple MLCC component package that isolates boardstress, provides a higher capacitance for a given footprint, and can bemanufactured with less limitations than current designs, is stilldesired for use in circuit layouts that have confined space requirementsand/or a harsh environment. In spite of the ongoing effort those ofskill in the art still seek an electrical package with multiple separatecomponents contained therein without the necessity of a common size forthe packaged components. Such an advance in the art is provided herein.

SUMMARY OF THE INVENTION

It is the object of the invention to provide an alternate method for anelectronic package containing multiple components, particularlyincluding MLCC's, that allows for variation in the form factor of thepackage and the content of components within the package.

A particular feature of the invention is the ability to provide anelectronic package wherein components of different shapes and sizes canbe commonly packaged while maintaining a footprint representative of asingle component.

These and other advantages, as will be realized, are provided in amodule comprising a multiplicity of electronic components wherein eachelectronic component comprises a first external termination with atleast one first longitudinal edge and a second external termination withat least one second longitudinal edge. A first lead is connected to thefirst longitudinal edge by a first interconnect and a second lead isconnected to the second longitudinal edge by a second interconnect.

Yet another embodiment is provided in a method for forming a module. Themethod comprises:

-   providing a multiplicity of electronic components wherein each    electronic component comprises a first external termination with at    least one first longitudinal edge and a second external termination    with at least on second longitudinal edge;-   placing a first lead into contact with the first longitudinal edge    with a first interconnect between the first lead and the first    longitudinal edge;-   placing a second lead into contact with the second longitudinal edge    with a second interconnect between the second lead and the second    longitudinal edge; and-   heating to form a bond of the first interconnect and the second    interconnect.

FIGURES

FIG. 1 is a schematic partial-cutaway side view of an embodiment of theinvention.

FIG. 2 is a schematic partial-cutaway end view of an embodiment of theinvention.

FIG. 3 is a schematic partial-cutaway side view of an embodiment of theinvention.

FIG. 4 is a schematic partial-cutaway bottom view of an embodiment ofthe invention.

FIG. 5 is a schematic partial-cutaway top view of an embodiment of theinvention.

FIG. 6 is a schematic partial-cutaway end view of an embodiment of theinvention.

FIG. 7 is a schematic partial-cutaway end view of an embodiment of theinvention.

FIG. 8 is a schematic partial-cutaway top view of an embodiment of theinvention.

FIG. 9 is a schematic partial-cutaway side view of an embodiment of theinvention.

FIGS. 10 and 10A are schematic partial-cutaway views of leads of theinvention.

FIG. 11 is a schematic partial-cutaway end view of an embodiment of theinvention.

FIG. 12 is a schematic partial-cutaway top view of an embodiment of theinvention.

FIG. 13 is a schematic partial-cutaway side view of an embodiment of theinvention.

FIG. 14 is a schematic partial-cutaway side view of an embodiment of theinvention.

FIG. 15 is a schematic partial-cutaway end view of an embodiment of theinvention.

FIG. 16 is a schematic view of leads of the invention.

FIG. 17 is a schematic partial-cutaway side view of an embodiment of theinvention.

FIG. 18 is a schematic partial-cutaway end view of an embodiment of theinvention.

FIG. 19 is a schematic partial-cutaway side view of an embodiment of theinvention.

FIG. 20 is an electrical schematic diagram of an embodiment of theinvention.

FIG. 21 is a schematic representation of an electronic component whereinthe longitudinal and end sections of the external termination aredistinguished.

DESCRIPTION

The instant invention is specific to an electrical component packagecomprising multiple components, preferably passive components includingmultilayered ceramic capacitor (MLCC) components, with commonterminations. More specifically, the present invention is related to anelectrical component package, or module, wherein the components can beof different sizes, shapes and functions yet commonly terminated.

The external terminations of at least some of the electronic componentsare commonly connected to leads, preferably plated ferrous ornon-ferrous material leads, with a high temperature conductive interfacematerial, or adhesive, and with or without an encapsulation/over moldingor pre-molded housing for use in an electrical circuit assembly. Theleads of the package may be formed for assembly to a printed circuitboard (PCB) as a surface mounted device (SMD) or as a through-holedevice. The component content and the lead frame and/or componentcarrier material, can be varied to provide custom package designs tomeet specific electrical circuit design requirements.

Combining multiple components, such as multiple MLCC's, within a commonelectrical package increases the functionality, such as capacitancevalue, beyond that available with the use of a single component whileutilizing a smaller footprint in an electrical circuit than the use ofequivalent single individual components. When using MLCC's, for example,the total capacitance value of the package is determined by the numberof MLCC's within the electronic package and the capacitance value ofeach individual MLCC. The instant invention allows for variation in notonly the quantity and mix of electronic components within a package butalso the geometric size of the component within the same package. Thisallows the electrical package to be designed with an increasedcapability to vary functionality within a package and offers a uniqueopportunity to provide, as an example, a more distinctive totalcapacitance value when employing MLCC's. This also allows for the use ofother, preferably passive, components thereby increasing thefunctionality available in a given space.

The method of attachment of the components to form the electricalpackage is critical to the integrity of the package during subsequentpart handling and assembly. With the use of high temperatureinterconnect materials in the form of a transient liquid phase sintering(TLPS) interconnect material, the electrical package, also referred toas an electrical assembly, is able to withstand subsequent hightemperature processing in the form of over molding and soldering and theelectrical package is able to withstand harsh electrical circuitenvironments. Other interconnect materials such as high temperaturesolders and conductive epoxies may be used as well to attach thecomponents but may have a more limited application. Attaching individualcomponents, particularly MLCC's, to a carrier material in the sameorientation as a typical surface mounted device (SMD) with contact onthe side or longitudinal face of the components external terminations,rather than that of the prior art along the end face of the externalterminations of the MLCC, removes the requirement for all components tobe of equal size. This form of attachment allows for multiple MLCCcomponents to be assembled in the form of a radial package in a smallerpackage outline than that of individual components. This differs fromthe prior art for radial packages where leads are soldered to thetermination end faces of a single MLCC component. This method ofattachment also allows the components to be assembled on opposing sidesof a lead frame. In the present invention it is preferred that the leadis attached to a longitudinal face with no lead attached to an end face.

Prior art for multiple MLCC modules are primarily in the form of stackswhere the leads are attached to the capacitor terminal ends as describedin U.S. Pat. Nos. 6,721,163; 8,988,857; 8,873,219; 6,958,899; 6,940,708and U.S. Pat. Appl. Publ. No. 20100243307. This requires that thecapacitors be sorted for size to ensure a robust interface with thelead. The instant invention eliminates the need for sorting capacitors,or other integrated components, by size because the lead is attached tothe longitudinal face of the components external termination. The secondcomponent in the stack is terminated through the first componentexternal terminations further eliminating component size sorting. Unlikethe prior art, the instant invention also allows the components to beassembled on opposing sides of the lead thereby providing a moreefficient method for packaging multiple components such as MLCCs. Theinstant invention also allows unsorted component sizes to be stacked andassembled to leads with the components in a vertical orientation.

Another advantage of the instant invention is the ability to assemblecomponents with different case sizes within the same electronic packageallowing more flexibility in module functionality. A further advantageof the instant invention is the ability to incorporate a combination ofdiscreet electronic components such as MLCC's, resistors, varistors,inductors, diodes, fuses, integrated circuits (IC), etc. into a commonelectrical package to create a custom electronic module. It ispreferable that at least one of the electronic components is an MLCC andmore preferably all of the components are MLCCs. Prior art in the formof a smart capacitor incorporates an alumina substrate with printedthick film materials to form a fuse and resistor as detailed in U.S.Pat. Nos. 8,904,609 and 8,264,816 rather than the use of discreetcomponents. Other prior art has used a lead frame to provide a fuse withan MLCC such as in U.S. Publ. Pat. Appl. Nos. 20140238732, 20140240941,20140240081, 20140240942 and 20140240885. Using discreet componentsallows increased flexibility in the assembly of the package withoutadding complexity to the module design. Discreet component values can bechanged quickly, easily, and without a large cost impact to meet therequirements of a circuit design.

The instant invention also allows for a method of assembly that utilizescurrent process technologies and common commercially available assemblyequipment. This provides for a more reasonable investment cost andimplementation timing.

The electronic package comprises multiple components, and preferably atleast one capacitor, attached to a carrier material, or lead, thatprovides a method of attachment in an electrical circuit with eitherthrough-hole, compliant pin, surface mount technologies, or otherinterconnect method.

An MLCC comprises first planar internal electrode layers in contact witha first external termination. Second planar internal electrode layersare interleaved with the first planar internal electrodes wherein thesecond planar internal electrodes contact a second external termination.A dielectric layer isolates the first planer internal planer electrodesfrom the second planer internal electrodes. The number of first andsecond planer internal electrodes, and the geometric size of thecomponents, determines the capacitance value of the device. Themanufacturing and structure of MLCC's is well known to those of skill inthe art and it is therefore not necessary for further discussion herein.

The invention will be described with reference to the various figuresforming an integral non-limiting component of the disclosure. Throughoutthe disclosure similar elements will be numbered accordingly.

An embodiment of the invention will be described with reference to FIGS.1 and 2 wherein an electronic package, generally represented at 100, isschematically illustrated in partial cut-away side view in FIG. 1 andpartial schematic cut-away end view in FIG. 2. The electroniccomponents, 1; individually representing an MLCC, a resistor, avaristor, an inductor, a diode, a fuse or an integrated circuit;comprise external terminations, 2, with at least one longitudinal edgeand preferably a longitudinal edge on each side of the component. Aninterconnect material 3 preferably selected from transient liquid phasesintering (TLPS) conductive interconnect material, conductive epoxy, orpolymer solder is along a longitudinal edge of the external termination,2, of each electronic component thereby electrically connecting a flatlead frame, 4, preferably of plated ferrous or non-ferrous material, tothe aligned external termination of each electronic component. The leadframes comprise a through-hole assembly stand-off feature, 5. The entireelectronic package is preferably encapsulated, 6, except for thestandoff feature, 5, and the terminal end of the lead frame 4. The leadframe may have a constant thickness or may be stamped, or coined, to bethinner in the component attachment region. In addition to the variationof the capacitance of the individual MLCC components, when multipleMLCCs are used, the number of components assembled in the package can bevaried with additional electronic components, 1 ^(n), added to theelectronic package to further define the total functionality of thepackage. In FIGS. 1 and 2, and elsewhere herein, the additionalelectronic components represented by 1^(n) are indicative of an integernumber of additional electronic components with the superscript “n”representing the integer number with “n” being an integer between 2 and100. For the purposes of the invention, the longitudinal edges are theside faces illustrated as “L” in FIG. 21 and are distinguished from theedge face illustrated as “E” in FIG. 21.

An embodiment of the invention will be described with reference to FIGS.3-6 wherein an electronic package is generally schematically representedat 101. The electronic package is represented in partial cut-away sideview in FIG. 3, in partial cut-away bottom view in FIG. 4, in partialcut-away top view in FIG. 5 and in partial cut-away side view in FIG. 6.In FIGS. 3-6 each electronic component, 1; individually representing anMLCC, a resistor, a varistor, an inductor, a diode, a fuse or anintegrated circuit; comprise external terminations, 2, on each sidewhich are electrically adhered to a round lead, 11, with an interconnectmaterial, 3, preferably selected from TLPS, conductive epoxy, or polymersolder, along the longitudinal edges of the terminations, 2. The longerlongitudinal surface can be mounted to the lead, as illustrated in FIG.6, or the shorter longitudinal surface can be mounted to the lead asillustrated elsewhere herein. The round lead, 11, is preferably a platedferrous or non-ferrous material comprising a coined flat terminal pad,12, and a through-hole assembly stand-off feature, 13. The entireelectronic package, except for the stand-off feature and terminal end ofthe round lead, is preferably encapsulated, 6. The number and type ofcomponents assembled in the package can be varied from 2 to 100 tofurther define the total capacitance of the package or to provideadditional functionality.

An embodiment of the invention will be described with reference to FIGS.7-9 wherein an electronic package is generally represented schematicallyat 102. The electronic package is illustrated in schematic partialcut-away end view In FIG. 7, in partial cut-away top view in FIG. 8 andin partial cut-away side view in FIG. 9. Each electronic component, 1,comprises external terminations, 2, on each side with at least onelongitudinal edge and preferably a longitudinal edge on each side. Forone row of electronic components, represented by 1², 1⁴, and 1^(m), thelongitudinal edge of the external terminations are in electric contactwith leads, 19, by interconnect material, 3, preferably selected fromTLPS, conductive epoxy, or polymer solder, along the longitudinal edgesof the terminations, 2. For a subsequent row of electronic components,represented by 1¹, 1³ and 1^(n), the longitudinal edge of the externalterminations are attached to the adjacent longitudinal edge of theexternal terminations of the first row of electronic components by aninterconnect material. The leads are preferably a flat lead frame ofplated ferrous or non-ferrous material comprising a through-holeassembly stand-off feature, 20. The entire electronic package except forthe stand-off feature and terminal end of the lead are preferablyencapsulated, 6, by coating, potting in a pre-molded housing, or otherencapsulation methods known in the art. An advantage of the invention ofFIGS. 7-9 is the ability to stack the component vertically andhorizontally, in rows and columns, with adjacent longitudinal edgesbonded by an interconnect thereby increasing the number of componentsincluded in the electronic package. It would be understood that thenumber of rows and columns can be quite large with up to 100 componentsbeing included in the assembly. Instead of the stand-off featureillustrated in FIGS. 7-9 a lead, 19, with a foot, 15, extending parallelto the lead, as illustrated schematically in FIG. 10, can be usedthereby providing a surface mount lead for an electronic package.Another option is to provide a compliant pin lead for mechanicalattachment as illustrated schematically in FIG. 10 a.

An embodiment of the invention will be described with reference to FIGS.11-13 wherein an electronic package, 103, is schematically illustratedin partial cut-away end view, FIG. 11, partial cut-away top view, FIG.12 and partial cut-away side view, FIG. 13. In FIGS. 11-13, anelectronic components, 1, of varying size are illustrated wherein eachcomponent comprises external terminations, 2, on opposite sides whereineach external termination has at least one longitudinal edge andpreferably multiple longitudinal edges. A laterally offset lead frame,22, has a lateral step thereby allowing electronic components to beplaced thereon wherein electronic components in a horizontal stack areof different lengths. Laterally offset, as defined herein, is defined asoffset in a plane parallel to the substrate upon which the electronicpackage is mounted. The laterally offset lead frame is illustrated withan optional stand-off feature, 21, with the understanding that a foot,as illustrated in FIG. 10, could be employed. On each side of a firstrow external termination are in electrical contact with the laterallyoffset lead frame by an interconnect material, 3, preferably selectedfrom TLPS, conductive epoxy, or polymer solder, along the longitudinaledges of the external terminations, 2. The laterally offset lead frameallows for an array of electronic components of different sizes with thesame electronic package. The entire electronic package, except for thestand-off feature and terminal end of the lead, are preferablyencapsulated, 6. An embodiment is illustrated in FIG. 18 wherein theshort longitudinal side of the electronic components are mounted to thelead frame, 63, and the lead frame has a foot, 64. For each embodimentthe electronic component can be mounted with either the longerlongitudinal side or the shorter longitudinal side in electrical contactwith the lead frame, or combinations thereof. In the embodimentsillustrated in FIGS. 11, 12, 13, 18 and elsewhere herein additional rowsand columns can be added with adjacent longitudinal edges of theexternal terminations bonded by an interconnect material which are notspecifically illustrated for clarity.

An embodiment of the invention will be described with reference to FIGS.14 and 15. FIG. 14 is a partial cut-away side schematic view of anelectronic package, generally represented at 104, and FIG. 15 is apartial cut-away edge schematic view. In FIGS. 14 and 15 a horizontallyoffset lead frame, 24, is utilized to accommodate electronic componentsof different sizes. Isolated horizontally offset lead frames areillustrated in schematic side view in FIG. 16. Horizontally offset, asdefined herein, is an offset in a plane perpendicular to the substrateupon which the electronic package is mounted.

An embodiment of the invention is illustrated in schematic cut-away sideview in FIG. 17 wherein a flat lead frame, 4, as described relative toFIG. 1, is incorporated with secondary flat lead frames, 41, wherein asecondary flat lead frame is in electrical contact with less than all ofthe electronic components of an electronic package. Lead frame, 4, forexample could be ground with each lead frame 41 having a differentfunctionality. It would be understood that additional capability can beincorporated with additional components being placed in electricalcontact with lead 4 and a select lead 41 either directly or through thelongitudinal edge of an adjacent component.

An advantage of the invention is the fact that each stack, extendingvertically away from the substrate is not limited in height by any otherstack.

Another option is to mount the components to the leads through theshorter of the longitudinal terminations as illustrated in FIG. 18. Thecomponents, 2 are bonded to the flat surface of the lead frame 63. Thelead surface for bonding is thus minimized.

An embodiment of the invention will be described with reference to FIG.19 wherein a plurality of horizontally offset lead frames are utilizedto form an electronic package with multiple functions. In FIG. 19, theelectronic package, generally represented by 105, comprises a firstcomponent, 86, with a horizontally offset lead frame in electricalcontact with each external termination, 286 and 287. One horizontallyoffset lead frame, 81, is also in electrical contact with an externaltermination 289 of a second component, 87. Another horizontally offsetlead frame is in electrical contact with external termination 286 ofcomponent 86 and external termination 291 of component 88. Horizontallyoffset lead frame 82 is in electrical contact with external termination290 of component 87 and external termination of component 88. As wouldbe realized from FIG. 19, the degree of offset can be varied dependingon the components employed and the combinations of components, 290,available is therefore very large in number. By way of non-limitingexample, if component 86 is an MLCC, component 87 is a diode and element88 is a resistor an electronic package can be prepared with anelectrical schematic diagram 89 as illustrated in FIG. 20.

A method of assembly could be easily implemented with the use ofstandard equipment and processes such as a lead frame carrier and/orpallet fixture for the part presentation and commercially availablemachines that are capable of applying interconnect materials, placingcomponents, performing inspection, curing/reflowing/sinteringinterconnect materials, trimming/forming leads, and encapsulating theassembly.

A through-hole assembly stand-off feature, as utilized herein, providesa physical barrier to the insertion of a through hole beyond a certaindepth.

Transient liquid phase sintering adhesives (TLPS) are conductivematerials that are distinguished from solders. Solders are alloys whichdo not undergo a change in composition after the first reflow. TLPSmaterials are mixtures of two or more metals or metal alloys prior toexposure to elevated temperatures. The second distinguishingcharacteristic of TLPS materials is that the melting point of thematerial is dependent on the thermal history of the material. TLPSmaterials exhibit a low melting point prior to exposure to elevatedtemperatures, and a higher melting point following exposure to thesetemperatures. The initial melting point is the result of the lowtemperature metal or an alloy of two low temperature metals. The secondmelting temperature is that of the intermetallic formed when the lowtemperature metal or alloy, forms a new alloy with a high temperaturemelting point metal thereby creating an intermetallic having a highermelting point. TLPS materials form a metallurgical bond between themetal surfaces to be joined. Unlike tin/lead or lead (Pb) free solders,the TLPS conductive adhesives do not spread as they form theintermetallic joint. Rework of the TLPS system is very difficult due tothe high secondary reflow temperatures.

Conductive adhesives comprise conductive metal, typically silver, filledpolymers that cure or cross link within a specified temperature range,generally 150° C., to form a mechanical bond to the materials to bejoined. Their conductivity is created by the metal particles which makeintimate contact with one another, within the confines of the polymermatrix, to form an electrically conductive path from one particle toanother. Because the binder is organic in nature, they have relativelylow temperature capabilities, normally in the range of about 150° C. toabout 300° C. Conductive epoxies, once cured, cannot be reworked.Conductive epoxies do not wet or flow as they cure as do solders whenthey melt.

Polymer solders may comprise conventional solder systems based on Pb/Snalloy systems or lead free systems, such as Sn/Sb, which are combinedwith cross linking polymers which serve as cleaning agents. Thecross-linked polymers also have the ability to form a cross-linkedpolymer bond, such as an epoxy bond, that forms during the melting phaseof the metals thereby forming a solder alloy and a mechanical polymericbond. An advantage of polymer solders is that the polymeric bondprovides additional mechanical bond strength at temperatures above themelting point of the solder, thus giving the solder joint a higheroperating temperature in the range of about 5 to 80° C. above themelting point of the solder. Polymer solders combine current solderalloys with a cross linking polymer within the same paste to provideboth a metallurgical bond and a mechanical bond when cured, such as byheating, to provide additional solder joint strength at elevatedtemperatures. However, the upper temperature limits and joint strengthhas been increased, just by the physical properties of the materials. Apractical limit of 300° C. remains whereas the transient liquid phasesintering conductive adhesives can achieve higher temperatures.

In use, conductive adhesives and conductive polymers can be coated ontoone side being bonded. With reference to FIG. 2, for example, theconductive adhesive can be placed on either the lead or the longitudinaledge. The component and lead can be placed into position with theinterconnect thereby between followed by heating to form the bond therebetween.

TLPS comprise high temperature materials selected from copper, silver,aluminum, gold, platinum, palladium, beryllium, rhodium, nickel, cobalt,iron and molybdenum or a mixture or any combination thereof are suitablefor use in transient liquid phase sintering conductive adhesives. Thelead (Pb) free transient liquid phase sintering adhesives preferably useeither silver or copper as the high temperature component and atin-bismuth alloy as the low temperature component.

TLPS further comprises low temperature materials selected from tin,antimony, bismuth, cadmium, zinc, gallium, indium, tellurium, mercury,thallium, selenium, or polonium, or a mixture or an alloy of any two ormore of these. The transient liquid phase sintering conductive adhesivesare compatible with surface finishes containing silver, tin, gold,copper, platinum, palladium, nickel, or combinations thereof, either aslead frame finishes, component connections or inner electrodes to forman electronically conductive metallurgical bond between two surfaces.Suitable external lead or lead frame materials include phosphor bronze,copper, alloys of copper such as but not limited to beryllium copper,Cu194 and Cu192, as well as lead frames consisting of ferrous alloyssuch as but not limited to Alloy 42 and Kovar.

A particular advantage of the TLPS is the flexibility provided inassembly. The high temperature component and low temperature componentcan be coated on one of the layers being bonded. With reference to FIG.2, the elements of the TLPS can be coated on either the lead or thelongitudinal edge and heated to form the bond after the component andlead are brought into relationship with the TLPS components therebetween. Alternatively, one component of the TLPS can be coated on thelead and the other coated on the longitudinal edge with heating afterthe component and lead are brought into relationship to form the bond.In a preferred embodiment, one component of the TLPS can be coated onone side being bonded, the lead for example, and the other component ofthe TLPS can be coated on the other side being bonded, an externaltermination for example. The components can be brought into contactfollowed by heating to form the TLPS bond.

The invention has been described with reference to the preferredembodiments without limit thereto. One of skill in the art would realizeadditional embodiments and improvements which are not specifically setforth herein but which are within the scope of the invention as morespecifically set forth in the claims appended hereto.

Claimed is:
 1. A module comprising: a multiplicity of electroniccomponents wherein each electronic component of said electroniccomponents comprises a first external termination with at least onefirst longitudinal edge and a second external termination with at leastone second longitudinal edge; a first lead connected to said firstlongitudinal edge by a first interconnect; a second lead connected tosaid second longitudinal edge by a second interconnect.
 2. The module ofclaim 1 wherein said first lead is connected to each first longitudinaledge by said first interconnect.
 3. The module of claim 1 wherein saidfirst lead is a flat plated lead with at least one said electroniccomponent on each side of said flat plated lead.
 4. The module of claim1 wherein said first lead frame comprises an offset.
 5. The module ofclaim 4 wherein said offset is selected from laterally offset andhorizontally offset.
 6. The module of claim 1 wherein said first lead isselected from a round lead frame and a flat lead.
 7. The module of claim6 wherein said first lead comprises at least one flattened region. 8.The module of claim 1 wherein said first lead is selected from athrough-hole lead, surface mount lead and a compliant pin lead.
 9. Themodule of claim 8 further comprising a through-hole assembly stand-offfeature.
 10. The module of claim 1 wherein said first lead comprises amaterial selected from a ferrous material and a non-ferrous material.11. The module of claim 1 wherein at least one of said firstinterconnect or said second interconnect is selected from the groupconsisting of a transient liquid phase sintering conductive interconnectmaterial, a conductive epoxy, polymer solder and a solder.
 12. Themodule of claim 1 wherein each said electronic component isindependently selected from the group consisting of a capacitor, adiode, a resistor, a varistor, an inductor, a fuse and an integratedcircuit.
 13. The module of claim 11 wherein at least one said electroniccomponent is a capacitor.
 14. The module of claim 13 wherein each saidelectronic component is a capacitor.
 15. The module of claim 14 whereineach said capacitor is an MLCC.
 16. The module of claim 1 wherein atleast two said electronic components have a different size.
 17. Themodule of claim 1 further comprising an encapsulation.
 18. The module ofclaim 1 comprising at least 2 electronic components to no more than 100electronic components.
 19. The module of claim 1 further comprising atleast one electronic component in a second row or a second columnwherein adjacent longitudinal edges are attached by an interconnect. 20.A method for forming a module comprising: providing a multiplicity ofelectronic components wherein each electronic component of saidelectronic components comprises a first external termination with atleast one first longitudinal edge and a second external termination withat least on second longitudinal edge; placing a first lead into contactwith said first longitudinal edge with a first interconnect between saidfirst lead and said first longitudinal edge; placing a second lead intocontact with said second longitudinal edge with a second interconnectbetween said second lead and said second longitudinal edge; and heatingto form a bond of said first interconnect and said second interconnect.21. The method for forming a module of claim 20 comprising bonding saidfirst lead to each first longitudinal edge by said first interconnect.22. The method for forming a module of claim 20 wherein said first leadis a flat plated lead with at least one said electronic component oneach side of said flat plated lead.
 23. The method for forming a moduleof claim 20 wherein said first lead frame comprises an offset.
 24. Themethod for forming a module of claim 23 wherein said offset is selectedfrom laterally offset and horizontally offset.
 25. The method forforming a module of claim 20 wherein said first lead is selected from around lead frame and a flat lead.
 26. The method for forming a module ofclaim 25 wherein said first lead comprises at least one flattenedregion.
 27. The method for forming a module of claim 20 wherein saidfirst lead is selected from a through-hole lead and a surface mountlead.
 28. The method for forming a module of claim 27 further comprisinga through-hole assembly stand-off feature.
 29. The method for forming amodule of claim 20 wherein said first lead comprises a material selectedfrom a ferrous material and a non-ferrous material.
 30. The method forforming a module of claim 20 wherein at least one of said firstinterconnect or said second interconnect is selected from the groupconsisting of a transient liquid phase sintering conductive interconnectmaterial, a conductive epoxy, a polymer solder and a solder.
 31. Themethod for forming a module of claim 20 wherein each said electroniccomponent is independently selected from the group consisting of acapacitor, a diode, a resistor, a varistor, an inductor, a fuse and anintegrated circuit.
 32. The method for forming a module of claim 31wherein at least one said electronic component is a capacitor.
 33. Themethod for forming a module of claim 32 wherein each said electroniccomponent is a capacitor.
 34. The method for forming a module of claim33 wherein each said capacitor is an MLCC.
 35. The method for forming amodule of claim 20 wherein at least two said electronic components havea different size.
 36. The method for forming a module of claim 20further comprising forming an encapsulation.
 37. The method for forminga module of claim 20 comprising at least 2 electronic components to nomore than 100 electronic components.
 38. The method for forming a moduleof claim 20 further comprising placing at least one electronic componentin a second row or a second column with an interconnect between adjacentlongitudinal edges and forming a bond of said interconnect.